CN112505153B - Technical feasibility analysis method and system for strain clamp crimping quality inspection - Google Patents
Technical feasibility analysis method and system for strain clamp crimping quality inspection Download PDFInfo
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- CN112505153B CN112505153B CN202010867345.2A CN202010867345A CN112505153B CN 112505153 B CN112505153 B CN 112505153B CN 202010867345 A CN202010867345 A CN 202010867345A CN 112505153 B CN112505153 B CN 112505153B
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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Abstract
The invention discloses a technical feasibility analysis method and a technical feasibility analysis system for strain clamp crimping quality inspection, wherein the method comprises the following steps: establishing a strain clamp model; based on a phased array ultrasonic detection technology combined with finite element simulation, performing simulation analysis on each crimping position in the strain clamp model to obtain simulation wall thickness data generated by the strain clamp model in the crimping process; detecting each crimping position of the strain clamp by using ultrasonic phased array equipment, and acquiring actual wall thickness data generated in the crimping process of the strain clamp; and obtaining error data between the simulated wall thickness data and the actual wall thickness data, and carrying out feasibility analysis on the application of the phased array ultrasonic detection technology based on the error data. In the embodiment of the invention, the accuracy and feasibility of the simulation analysis method can be verified by combining the error judgment of the simulation analysis method and the actual measurement method, and the method has important significance for quality judgment of the strain clamp.
Description
Technical Field
The invention relates to the technical field of electric power, in particular to a technical feasibility analysis method and a technical feasibility analysis system for strain clamp crimping quality inspection.
Background
In an electric power system, a wire for realizing remote transmission is generally connected by adopting a strain clamp in a hydraulic pressure crimping manner, and the crimping quality of the strain clamp is generally judged by adopting a traditional manner of measuring the outer diameter, but the traditional manner has certain limitation because the wall thickness of the strain clamp can be changed along with the crimping pressure, the crimping speed and other factors, so that the internal crimping quality of the strain clamp cannot be intuitively judged and analyzed, and if the strain clamp with quality problems is used on a transmission line, potential safety hazards can be caused. Therefore, a technical staff puts forward an ultrasonic phased array detection method combined with finite element simulation to solve the problem of judging the internal quality of the strain clamp, but the feasibility of the method is not verified.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, provides a technical feasibility analysis method and a technical feasibility analysis system for quality inspection of strain clamps, can effectively verify the feasibility of an ultrasonic phased array detection technology combined with finite element simulation, and has important significance for quality judgment of the strain clamps.
In order to solve the problems, the invention provides a technical feasibility analysis method applied to strain clamp crimping quality inspection, which comprises the following steps:
establishing a strain clamp model;
based on a phased array ultrasonic detection technology combined with finite element simulation, performing simulation analysis on each crimping position in the strain clamp model to obtain simulation wall thickness data generated by the strain clamp model in the crimping process;
detecting each crimping position of the strain clamp by using ultrasonic phased array equipment, and acquiring actual wall thickness data generated in the crimping process of the strain clamp;
and obtaining error data between the simulated wall thickness data and the actual wall thickness data, and carrying out feasibility analysis on the application of the phased array ultrasonic detection technology based on the error data.
Optionally, the performing simulation analysis on each crimping position in the strain clamp model based on the phased array ultrasonic detection technology combined with finite element simulation includes:
constructing a pressure acoustic constitutive equation;
the strain clamp model is led into the pressure acoustic constitutive equation, and finite element meshing is conducted on the strain clamp model;
based on the excitation signals obtained through modulation, carrying out simulation calculation on the divided strain clamp model, and obtaining simulation wall thickness data corresponding to each crimping position of the strain clamp model.
Optionally, the pressure acoustic constitutive equation includes:
p t ＝p+p b
wherein ρ is the density of the medium, c is the propagation speed of the sound wave in the medium, p is the sound pressure, p b For background pressure, p t For the total pressure, t is the propagation time,
gradient, q d Is a monopolar source, Q m Is a dipole source (applied to the piezoelectric transducer).
Optionally, the excitation signal obtained by modulation is:
wherein A is the pulse amplitude of the excitation signal, sigma is the pulse standard deviation of the excitation signal, f is the frequency of the excitation signal, and t is the time.
In addition, the embodiment of the invention also provides a technical feasibility analysis system for strain clamp crimping quality inspection, which comprises the following steps:
the building module is used for building a strain clamp model;
the simulation module is used for performing simulation analysis on each compression joint position in the strain clamp model based on a phased array ultrasonic detection technology combined with finite element simulation, and obtaining simulation wall thickness data generated in the compression joint process of the strain clamp model;
the detection module is used for detecting each crimping position of the strain clamp by utilizing ultrasonic phased array equipment and acquiring actual wall thickness data generated in the crimping process of the strain clamp;
and the analysis module is used for acquiring error data between the simulated wall thickness data and the actual wall thickness data and carrying out feasibility analysis on the application of the phased array ultrasonic detection technology based on the error data.
Optionally, the simulation module is used for constructing a pressure acoustic constitutive equation; the strain clamp model is led into the pressure acoustic constitutive equation, and finite element meshing is conducted on the strain clamp model; based on the excitation signals obtained through modulation, carrying out simulation calculation on the divided strain clamp model, and obtaining simulation wall thickness data corresponding to each crimping position of the strain clamp model.
Optionally, the pressure acoustic constitutive equation includes:
p t ＝p+p b
wherein ρ is the density of the medium, c is the propagation speed of the sound wave in the medium, p is the sound pressure, p b For background pressure, p t For the total pressure, t is the propagation time,
gradient, q d Is a monopolar source, Q m Is a dipole source (applied to the piezoelectric transducer).
Optionally, the excitation signal obtained by modulation is:
wherein A is the pulse amplitude of the excitation signal, sigma is the pulse standard deviation of the excitation signal, f is the frequency of the excitation signal, and t is the time.
In the embodiment of the invention, the feasibility of detecting the internal quality of the strain clamp by the ultrasonic phased array detection technology can be truly and effectively verified through the theoretical result obtained by combining the ultrasonic phased array detection technology of finite element simulation and the actual result detected by the ultrasonic phased array equipment, and the method has important significance for safe application of the strain clamp on a transmission line.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings which are required in the description of the embodiments or the prior art will be briefly described, it being obvious that the drawings in the description below are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic flow chart of a technical feasibility analysis method for strain clamp crimping quality inspection, disclosed in an embodiment of the invention;
FIG. 2 is a diagram of simulation analysis of the crimping position of a steel core and a steel anchor disclosed in the embodiment of the invention;
FIG. 3 is a diagram of a simulation analysis of the crimp location of a notch and an aluminum sleeve disclosed in an embodiment of the present invention;
FIG. 4 is a simulation analysis diagram of the crimping position of an aluminum stranded wire and an aluminum sleeve according to the embodiment of the invention;
FIG. 5 is a phased array imaging of various crimp locations for strain clamps as disclosed in embodiments of the present invention;
fig. 6 is a structural diagram of a technical feasibility analysis system for strain clamp crimping quality inspection according to an embodiment of the invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Fig. 1 shows a flow chart of a technical feasibility analysis method for strain clamp crimping quality inspection, which comprises the following steps:
s101, establishing a strain clamp model;
according to GB/T1179-2017, the strain clamp model with model number NY-240/40 which tends to be idealized is built by utilizing three-dimensional software, and the assembly between the clamp body model and the wire model is completed after the clamp body model and the wire model are respectively built. The wire clamp body model is used for clearly expressing the crimping positions of the steel core and the steel anchor, the crimping positions of the aluminum stranded wires and the aluminum sleeve and the crimping positions of the notch and the aluminum sleeve.
S102, performing simulation analysis on each compression joint position in the strain clamp model based on a phased array ultrasonic detection technology combined with finite element simulation, and obtaining simulation wall thickness data generated in the compression joint process of the strain clamp model;
the specific implementation process is as follows:
(1) The pressure acoustic constitutive equation is constructed as follows:
p t ＝p+p b
wherein ρ is the density of the medium, c is the propagation speed of the sound wave in the medium, p is the sound pressure, p b For background pressure, p t For the total pressure, t is the propagation time,
gradient, q d Is a monopolar source, Q m Is a dipole source (applied to the piezoelectric transducer).
(2) The strain clamp model is led into the pressure acoustic constitutive equation, and finite element meshing is conducted on the strain clamp model;
in the embodiment of the invention, firstly, the strain clamp model is imported into the pressure acoustic constitutive equation, and secondly, defining the material parameters of each model comprises the following steps: the aluminum sleeve is made of AA1050 pure aluminum, the steel anchor is made of Q195 engineering structural steel, the piezoelectric ceramic is made of PZT-5A ceramic, and the maximum allowable size of the grid is 0.063mm when simulation is obtained by combining the frequency adopted by simulation with the wavelength formula lambda=v/f according to the fact that the maximum allowable size of the grid during simulation cannot exceed one fifth of the wavelength.
(3) Based on the excitation signals obtained through modulation, carrying out simulation calculation on the divided strain clamp model, and obtaining simulation wall thickness data corresponding to each crimping position of the strain clamp model.
In the embodiment of the invention, as the strain clamp is clamped by the actual hydraulic pressure and the air cavities with irregular shapes are formed between different joint surfaces of the workpiece, when the ultrasonic waves propagate in the workpiece, the phenomenon of refraction and reflection of the acoustic waves occurs based on the existence of the air cavities, so that cavity echoes related to the pressure quality detection are formed, and the ultrasonic waves of other parts continue to propagate until the material boundary is reflected.
The analysis and judgment of the cavity echo signals are realized by adopting a phased array ultrasonic detection technology, namely, receiving and transmitting of 64 array elements are performed through a one-dimensional linear phased array probe, and 8 array elements are excited simultaneously each time to receive the cavity echoThe signal is used for obtaining the sound pressure of the cavity echo signal through the vector superposition principle. Firstly, setting delay time t of focusing effect to be achieved by linear array transducer according to phased emission focusing principle fn The method comprises the following steps:
wherein n is the array element serial number, F is the focal length, c is the medium sound velocity, d is the array element center distance, t 0 Is a time constant, and the value of the time constant should be large enough to avoid t fn Negative values occur;
secondly, modulating a sinusoidal signal by using a Gaussian window function, and obtaining an excitation signal obtained by modulation as follows:
wherein A is the pulse amplitude of the excitation signal, sigma is the pulse standard deviation of the excitation signal, f is the frequency of the excitation signal, t is the time, and the delay time is obtained according to the previous time.
Finally, a wall thickness solving formula provided by combining pulse reflection method
(/>
For the time difference from transmitting to receiving of ultrasonic waves), simulation is performed by using the excitation signal, and simulation wall thickness data corresponding to each crimping position of the tension-resistant line pressure model can be obtained, wherein the simulation wall thickness data comprises the following steps:
a. wall thickness data of crimping position of steel core and steel anchor
Fig. 2 shows a simulated analysis diagram of the crimp position of the steel core and the steel anchor in the embodiment of the invention, wherein the diagram B describes the sound pressure curve obtained by reflecting the ultrasonic wave when encountering the cavity inside the crimp position, and the diagram B can be known: the first waveform isStart wave, get to 2 x 10 -6 s, a cavity echo is obtained, and the time difference for reading the cavity echo is 1.52 x 10 -6 s, obtaining wall thickness data corresponding to the crimping position to be 4.48mm through calculation;
b. wall thickness data of crimping position of notch and aluminum sleeve
FIG. 3 is a graph of a simulated analysis of the crimp location of a notch and an aluminum sleeve in an embodiment of the invention, wherein graph B depicts the sound pressure curve of an ultrasonic wave reflected from a cavity inside the crimp location, as follows: the first waveform is the initial waveform, which reaches 3×10 -6 s, a cavity echo is obtained, and the time difference for reading the cavity echo is 2.4 x 10 -6 s, obtaining wall thickness data corresponding to the crimping position to be 7.56mm through calculation;
c. wall thickness data of crimping position of aluminum stranded wire and aluminum sleeve
Fig. 4 shows a simulation analysis diagram of a crimp position of an aluminum stranded wire and an aluminum sleeve in an embodiment of the invention, wherein a diagram B depicts a sound pressure curve obtained by reflecting an ultrasonic wave when encountering a cavity inside the crimp position, and it can be known that: the first waveform is the initial waveform, which reaches 3×10 -6 s, a cavity echo is obtained, and the time difference for reading the cavity echo is 2.11 x 10 - 6 And s, calculating to obtain the wall thickness data corresponding to the crimping position of 6.65mm.
S103, detecting each crimping position of the strain clamp by using ultrasonic phased array equipment, and acquiring actual wall thickness data generated in the crimping process of the strain clamp;
in the embodiment of the invention, fig. 5 shows a phased array imaging diagram of each crimping position of the strain clamp in the embodiment of the invention, the imaging result shows the size of the cavity, and the wall thickness data of each crimping position of the strain clamp can be directly measured through an ultrasonic phased array device (namely a multi-pump Phascan type detector). Here, 5 strain clamps are used for carrying out compression joint quality detection according to DL/T5285-2018 "transmission and transformation project overhead conductor (below 800mm 2) and ground wire hydraulic compression joint technical specification", and three compression joint positions on each strain clamp show a regular hexagon structure after compression joint, and corresponding detection results are shown in table 1:
table 1 wall thickness data record table for each crimping position
| Workpiece numbering | 1 | 2 | 3 | 4 | 5 |
| Steel anchor and steel core crimping | 4.00 | 4.04 | 4.19 | 4.15 | 4.00 |
| Notch and aluminum sleeve crimping | 7.20 | 6.85 | 7.15 | 7.00 | 6.70 |
| Aluminum stranded wire and aluminum sleeve crimping | 6.46 | 6.45 | 6.59 | 6.67 | 6.34 |
As is clear from Table 1, the average depth of the 5 strain clamps at the crimp positions of the steel anchors and the steel cores was 4.08mm, the average depth of the 5 strain clamps at the crimp positions of the notches and the aluminum bushings was 6.98mm, and the average depth of the 5 strain clamps at the crimp positions of the aluminum strands and the aluminum bushings was 6.50mm.
S104, acquiring error data between the simulated wall thickness data and the actual wall thickness data, and carrying out feasibility analysis on the application of the phased array ultrasonic detection technology based on the error data.
In the embodiment of the present invention, the wall thickness data of the strain clamp corresponding to step S102 and step S103 are combined, which can be known as follows: the error value between the simulated wall thickness data of 4.48mm and the actual wall thickness data of 4.08mm at the crimping position of the steel anchor and the steel core is 9.8%, the error value between the simulated wall thickness data of 7.56mm and the actual wall thickness data of 6.98mm at the crimping position of the notch and the aluminum sleeve is 8.3%, the error value between the simulated wall thickness data of 6.65mm and the actual wall thickness data of 6.50mm at the crimping position of the aluminum stranded wire and the aluminum sleeve is 2.3%, and the error values are less than 20% on the whole, namely the fact that the phased array ultrasonic detection technology combined with the finite element simulation is applied to the wall thickness detection after the strain clamp crimping has accurate reliability, and has important significance for the safe use of the strain clamp on a line.
Fig. 6 shows a structural composition diagram of a technical feasibility analysis system for strain clamp crimping quality inspection, which is disclosed in an embodiment of the invention, and comprises:
the establishing module 201 is used for establishing a strain clamp model;
the simulation module 202 is used for performing simulation analysis on each crimping position in the strain clamp model based on a phased array ultrasonic detection technology combined with finite element simulation, and obtaining simulation wall thickness data generated in the crimping process of the strain clamp model;
specifically, the simulation module 202 is configured to construct a pressure acoustic constitutive equation:
p t ＝p+p b
wherein ρ is the density of the medium, c is the propagation speed of the sound wave in the medium, p is the sound pressure, p b For background pressure, p t For the total pressure, t is the propagation time,
gradient, q d Is a monopolar source, Q m Is a dipole source (applied to the piezoelectric transducer).
The simulation module 202 is further configured to introduce the strain clamp model into the pressure acoustic constitutive equation, and perform finite element meshing on the strain clamp model; based on the excitation signals obtained through modulation, carrying out simulation calculation on the divided strain clamp model, and obtaining simulation wall thickness data corresponding to each crimping position of the strain clamp model, wherein the excitation signals obtained through modulation are as follows:
wherein A is the pulse amplitude of the excitation signal, sigma is the pulse standard deviation of the excitation signal, f is the frequency of the excitation signal, and t is the time.
The detection module 203 is configured to detect each crimping position of a strain clamp by using an ultrasonic phased array device, and obtain actual wall thickness data generated in a crimping process of the strain clamp;
and the analysis module 204 is used for acquiring error data between the simulated wall thickness data and the actual wall thickness data and carrying out feasibility analysis on the application of the phased array ultrasonic detection technology based on the error data.
The system is configured to execute the above technical feasibility analysis method for quality inspection of tension clamp crimp, and for the specific implementation of each module in the system, please refer to the method flowchart shown in fig. 1 and specific implementation content, which are not described herein again.
In the embodiment of the invention, the feasibility of detecting the internal quality of the strain clamp by the ultrasonic phased array detection technology can be truly and effectively verified through the theoretical result obtained by combining the ultrasonic phased array detection technology of finite element simulation and the actual result detected by the ultrasonic phased array equipment, and the method has important significance for safe application of the strain clamp on a transmission line.
Those of ordinary skill in the art will appreciate that all or part of the steps in the various methods of the above embodiments may be implemented by a program to instruct related hardware, the program may be stored in a computer readable storage medium, and the storage medium may include: read Only Memory (ROM), random access Memory (RAM, random Access Memory), magnetic or optical disk, and the like.
The technical feasibility analysis method and system for strain clamp crimping quality inspection provided by the embodiment of the invention are described in detail, and specific examples are adopted to illustrate the principle and implementation of the invention, and the description of the above embodiments is only used for helping to understand the method and core ideas of the invention; meanwhile, as those skilled in the art will have variations in the specific embodiments and application scope in accordance with the ideas of the present invention, the present description should not be construed as limiting the present invention in view of the above.
Claims (6)
1. A technical feasibility analysis method for strain clamp crimping quality inspection, the method comprising:
establishing a strain clamp model;
based on a phased array ultrasonic detection technology combined with finite element simulation, performing simulation analysis on each crimping position in the strain clamp model to obtain simulation wall thickness data generated by the strain clamp model in the crimping process;
detecting each crimping position of the strain clamp by using ultrasonic phased array equipment, and acquiring actual wall thickness data generated in the crimping process of the strain clamp;
obtaining error data between the simulated wall thickness data and the actual wall thickness data, and carrying out feasibility analysis on the application of the phased array ultrasonic detection technology based on the error data;
the phased array ultrasonic detection technology based on the combination of finite element simulation carries out simulation analysis on each compression joint position in the strain clamp model, and the simulation analysis comprises the following steps:
constructing a pressure acoustic constitutive equation;
the strain clamp model is led into the pressure acoustic constitutive equation, and finite element meshing is conducted on the strain clamp model;
based on the excitation signals obtained through modulation, performing simulation calculation on the divided strain clamp model to obtain simulation wall thickness data corresponding to each crimping position of the strain clamp model;
wherein ρ is the density of the medium, c is the propagation speed of the sound wave in the medium, p is the sound pressure, p b For background pressure, p t For the total pressure, t is the propagation time,
gradient, q d Is a monopolar source, Q m Is a dipole source, Q m Applied to the piezoelectric sensor.
2. The technical feasibility analysis method for strain clamp crimping quality inspection according to claim 1, wherein the excitation signal obtained by modulation is:
wherein A is the pulse amplitude of the excitation signal, sigma is the pulse standard deviation of the excitation signal, f is the frequency of the excitation signal, and t is the time.
3. A system for performing the technical feasibility analysis method for strain clamp crimping quality inspection according to any of claims 1-2, characterized in that the system comprises:
the building module is used for building a strain clamp model;
the simulation module is used for performing simulation analysis on each compression joint position in the strain clamp model based on a phased array ultrasonic detection technology combined with finite element simulation, and obtaining simulation wall thickness data generated in the compression joint process of the strain clamp model;
the detection module is used for detecting each crimping position of the strain clamp by utilizing ultrasonic phased array equipment and acquiring actual wall thickness data generated in the crimping process of the strain clamp;
and the analysis module is used for acquiring error data between the simulated wall thickness data and the actual wall thickness data and carrying out feasibility analysis on the application of the phased array ultrasonic detection technology based on the error data.
4. The system of claim 3, wherein the simulation module is configured to construct a pressure acoustic constitutive equation; the strain clamp model is led into the pressure acoustic constitutive equation, and finite element meshing is conducted on the strain clamp model; based on the excitation signals obtained through modulation, carrying out simulation calculation on the divided strain clamp model, and obtaining simulation wall thickness data corresponding to each crimping position of the strain clamp model.
5. The system of claim 4, wherein the pressure acoustic constitutive equation comprises:
p t ＝p+p b
wherein ρ is the density of the medium, c is the propagation speed of the sound wave in the medium, p is the sound pressure, p b For background pressure, p t For the total pressure, t is the propagation time,
gradient, q d Is a monopolar source, Q m Is a dipole source, Q m Applied to the piezoelectric sensor.
6. The system of claim 4, wherein the modulated excitation signal is:
wherein A is the pulse amplitude of the excitation signal, sigma is the pulse standard deviation of the excitation signal, f is the frequency of the excitation signal, and t is the time.
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| CN113779845B (en) * | 2021-09-18 | 2023-05-23 | 国网四川省电力公司电力科学研究院 | Strain clamp crimping process optimization method and device based on finite element simulation |
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